Oxygenator antithrombotic coating and method of manufacture

ABSTRACT

Hollow fiber membranes in an oxygenator for an extracorporeal blood circulator are coated with an antithrombotic polymeric material. The porous hollow fiber membranes for gas exchange have outer surfaces, inner surfaces forming lumens, opening portions through which the outer surfaces communicate with the inner surfaces in a housing. A blood flow path is outside of the hollow fiber membrane bundle in the housing, between a blood inlet port and a blood outlet port. The coating is obtained by filling the blood flow path with a colloidal solution containing an antithrombotic polymeric compound, and moving the colloid solution between the blood inlet port and the blood outlet port for a time that coats a predetermined amount of antithrombotic polymeric compound on the outer surfaces of the hollow fiber membranes. Other surfaces within the oxygenator contacting the blood flow likewise receive the coating.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of PCT Application No.PCT/JP2019/000545, filed Jan. 10, 2019, based on and claiming priorityto Japanese Application No. 2018-001806, filed Jan. 10, 2018, both ofwhich are incorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION

The present invention relates to a method for manufacturing anoxygenator. More specifically, the present invention relates to a methodfor manufacturing a hollow fiber membrane oxygenator of an outside bloodflow type that includes removing carbon dioxide in blood and addingoxygen to blood in extracorporeal blood circulation, and an oxygenator.

Generally, a hollow fiber membrane type oxygenator using porousmembranes is widely used as an extracorporeal circulator or anartificial heart-lung apparatus for assisting circulation in open heartsurgery for a heart disease. The hollow fiber membranes are used formembrane type oxygenators. Gas exchange in blood is performed throughthese hollow fiber membranes. As a system of blood flow to theoxygenator, there are an inside flow system in which the blood flowsinside of the hollow fiber membranes and gas flows outside of the hollowfiber membranes, and an outside flow system in which, by comparison, theblood flows outside of the hollow fiber membranes and gas flows insideof the hollow fiber membranes.

In hollow fiber membrane type oxygenators, inner surfaces or outersurfaces of the hollow fiber membranes are in contact with the blood.Therefore, there is a concern that the inner surfaces or the outersurfaces of the hollow fiber membranes in contact with the blood mayaffect adhesion (attachment) or activation of the platelet system.Particularly, an outside flow type oxygenator in which the outersurfaces of the hollow fiber membranes are in contact with the bloodcauses disruption of a blood flow, which more readily causes adhesion(attachment) or activation of the platelet system.

Considering such problems, and in view of the suppression and preventioneffects of alkoxyalkyl(meth)acrylate on adhesion or activation of theplatelet system, as an antithrombotic material,alkoxyalkyl(meth)acrylate has been used for coating the blood-contactingsurface of hollow fiber membranes of an outside flow type oxygenator.For example, U.S. Pat. No. 6,495,101 B1 discloses a coating method inwhich outside surfaces or outer surface layers of the hollow fibermembranes are coated with a coating solution obtained by dissolving apolymer containing alkoxyalkyl(meth)acrylate as a main component in amixed solvent of water, methanol, and ethanol, and then dried.

According to the technique disclosed in U.S. Pat. No. 6,495,101 B1,during the coating process, the coating solution inadvertentlypenetrates into fine holes (opening portions) from outer surfaces of thehollow fiber membranes, and a part of an inner wall adjacent to the fineholes in the vicinity of the blood flow path side likewise becomescoated with an antithrombotic polymeric compound (antithromboticpolymeric material). When the blood circulates in such an oxygenator,blood plasma components infiltrate into the fine holes along the coatingof the antithrombotic polymeric compound formed on the inner wall aroundthe fine holes because of hydrophilicity of the antithrombotic polymericcompound. As a result, this causes leakage of the blood plasmacomponents from the blood flow path side to the gas flow path side.

In order to solve this problem, the inventors of the present inventionhave prepared a colloidal solution containing an antithromboticpolymeric compound having a predetermined particle size which inhibitsmigration through the fine holes, and tried to use a method of coatingthe surfaces of the hollow fiber membranes using the colloidal solution.However, it has been found that this method causes a new problem whereinit is difficult to coat the surfaces of the hollow fiber membranes witha sufficient amount of the antithrombotic polymeric compound.

SUMMARY OF THE INVENTION

Therefore, the present invention has been made in view of the abovecircumstances, and an object of the present invention is to provide aprocedure that can increase a coating amount of the antithromboticpolymeric compound on the hollow fiber membranes in the method formanufacturing an oxygenator using the colloidal solution containing theantithrombotic polymeric compound.

The inventors of the present invention have conducted intensive studiesto solve the above problems. As a result, they have found that the aboveproblems can be overcome by filling a blood flow path with a colloidalsolution of an antithrombotic polymeric compound, and coating hollowfiber membranes while moving the colloidal solution, and have completedthe present invention.

That is, the object can be achieved by a method for manufacturing anoxygenator having a hollow fiber membrane bundle with a plurality ofporous hollow fiber membranes for gas exchange which have outersurfaces, inner surfaces forming lumens, opening portions (e.g., fineholes) through which the outer surfaces communicate with the innersurfaces in a housing, a blood flow path which is outside of the hollowfiber membrane bundle in the housing, a blood inlet port in an upperposition of the blood flow path, and a blood outlet port in a lowerposition of the blood flow path, the method including: filling the bloodflow path with a colloidal solution containing an antithromboticpolymeric compound; and moving the colloid solution between the bloodinlet port and the blood outlet port. Furthermore, the object isachieved by an oxygenator for an extracorporeal blood circulator,comprising: a housing having a blood inlet port, a blood outlet port,and housing surfaces for defining a blood flow path in an inner chamber;a hollow fiber membrane bundle retained in the inner chamber with aplurality of porous hollow fiber membranes for gas exchange which haveouter surfaces, inner surfaces forming lumens, and opening portionsthrough which the outer surfaces communicate with the inner surfaces,wherein the blood flow path passes over the outside surfaces of thehollow fiber membranes in the inner chamber; and a coating of anantithrombotic polymeric compound on the outside surfaces of the hollowfiber membranes; wherein the coating is deposited on the outsidesurfaces of the hollow fiber membranes by filling the blood flow pathwith a colloidal solution containing an antithrombotic polymericcompound, and moving the colloidal solution along the blood flow pathbetween the blood inlet port and the blood outlet port for a time thatcoats a predetermined amount of antithrombotic polymeric compound on theouter surfaces of the hollow fiber membranes.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a cross-sectional view showing one embodiment of a hollowfiber membrane oxygenator of an outside blood flow type according to thepresent invention;

FIG. 2 is an enlarged cross-sectional view of a hollow fiber membraneused in the hollow fiber membrane oxygenator of an outside blood flowtype according to the present invention;

FIG. 3 is a cross-sectional view showing another embodiment of a hollowfiber membrane oxygenator of an outside blood flow type according to thepresent invention;

FIG. 4 is a cross-sectional view taken along line A-A of FIG. 3;

FIG. 5 is a front view showing an example of an inner tubular memberused in the hollow fiber membrane oxygenator of an outside blood flowtype according to the present invention;

FIG. 6 is a central longitudinal cross-sectional view of the innertubular member shown in FIG. 5;

FIG. 7 is a cross-sectional view taken along line B-B of FIG. 5;

FIG. 8 is a graph showing coating amounts in Examples of the inventionand a Comparative Example; and

FIG. 9 is a graph showing colloid use efficiencies in Examples andComparative Example.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention relates to a method for manufacturing anoxygenator having a hollow fiber membrane bundle with a plurality ofporous hollow fiber membranes for gas exchange which have outersurfaces, inner surfaces forming lumens, opening portions through whichthe outer surfaces communicate with the inner surfaces in a housing, ablood flow path which is outside of the hollow fiber membrane bundle inthe housing, a blood inlet port in an upper position of the blood flowpath, and a blood outlet port in a lower position of the blood flowpath, the method including: filling the blood flow path with a colloidalsolution containing an antithrombotic polymeric compound; andcirculating the colloid solution between the blood inlet port and theblood outlet port. According to the present invention, in the method formanufacturing an oxygenator using the colloidal solution containing theantithrombotic polymeric compound, the coating amount of theantithrombotic polymeric compound on the hollow fiber membranes can beincreased.

In the method for manufacturing an oxygenator according to the presentinvention, in the hollow fiber membrane oxygenator of an outside bloodflow type, a blood flow path is filled with the colloidal solutioncontaining the antithrombotic polymeric compound, and the colloidalsolution is circulated (e.g., moved) between the blood inlet port andthe blood outlet port, whereby the coating amount of the antithromboticpolymeric compound can be increased. The mechanism in which the aboveeffect is exerted through such a process is not clear, but the inventorsof the present invention speculate as follows. The present invention isnot limited to the following mechanism.

The colloid particles (surfaces of particles) and the surfaces of thehollow fiber membranes in the colloidal solution containing theantithrombotic polymeric compound are typically negatively charged. Forthis reason, the colloid particles repel other colloid particles presentin the surroundings, and also repel the surfaces of the hollow fibermembranes. Accordingly, it has been difficult to coat the surfaces ofthe hollow fiber membranes with a sufficient amount of the colloidparticles (the antithrombotic polymeric compound). In the presentinvention, the blood flow path is filled with the colloidal solution,and the colloidal solution is moved between the blood inlet port and theblood outlet port, whereby the colloid particles can collide with thesurfaces of the hollow fiber membranes. As described above, it isconsidered that the colloid particles collide with the surfaces of thehollow fiber membranes with energy larger than the electric repulsiveforce, so that the colloid particles are easily fixed to the surfaces ofthe hollow fiber membranes, and the coating amount of the antithromboticpolymeric compound is increased.

In addition, the colloidal solution is circulated, whereby the number oftimes that colloid particles come into contact with the surfaces of thehollow fiber membranes can be increased as compared with a case wherethe colloidal solution is allowed to stand. For this reason, even in acase where a colloidal solution having a low colloid concentration isused, it is possible to coat the surfaces of the hollow fiber membraneswith a sufficient amount of the antithrombotic polymeric compound (i.e.,it is possible to improve the colloid use efficiency in the colloidalsolution).

Hereinafter, preferred embodiments of the present invention will bedescribed. Note that the present invention is not limited to only thefollowing embodiments. In addition, dimensional ratios in the drawingsare exaggerated for convenience of description, and may be differentfrom actual dimensional ratios.

In the present specification, “X to Y” indicating a range includes X andY, and means “X or more and Y or less”. Unless otherwise specified,operation and measurements of physical properties or the like areperformed under conditions of room temperature (20° C. to 25° C.) and arelative humidity of 40 to 50% RH.

One aspect of the present invention is a method for manufacturing anoxygenator having a hollow fiber membrane bundle with a plurality ofporous hollow fiber membranes for gas exchange which have outersurfaces, inner surfaces forming lumens, opening portions through whichthe outer surfaces communicate with the inner surfaces in a housing, ablood flow path which is outside of the hollow fiber membrane bundle inthe housing, a blood inlet port in an upper position of the blood flowpath, and a blood outlet port in a lower position of the blood flowpath, the method including: filling the blood flow path with a colloidalsolution containing an antithrombotic polymeric compound; and moving thecolloid solution between the blood inlet port and the blood outlet port.

Hereinafter, the method for manufacturing an oxygenator of the presentinvention will be described in detail. In the present specification, forconvenience, an oxygenator obtained by the manufacturing method of thepresent invention will be first described, and then the manufacturingmethod of the present invention will be described.

FIG. 1 is a cross-sectional view of one embodiment of a hollow fibermembrane oxygenator of an outside blood flow type according to thepresent invention. FIG. 2 is an enlarged cross-sectional view of poroushollow fiber membranes for gas exchange used in the hollow fibermembrane oxygenator of an outside blood flow type according to thepresent invention. FIG. 3 is a cross-sectional view of anotherembodiment of an oxygenator according to the present invention.

In FIG. 1, an oxygenator 1 is an oxygenator of a type in which a largenumber of porous hollow fiber membranes 3 for gas exchange areaccommodated in a housing 2. The blood flows around and over the outerside of the hollow fiber membranes 3, and an oxygen-containing gas flowsthrough the inside of the hollow fiber membranes 3. In FIG. 2, anantithrombotic polymeric compound 18 coats the outside surface of thehollow fiber membrane 3 which serves as the blood contact portion (anouter surface 3 a′, or an outer surface 3 a′, and an outer surface layer3 a). The coat (coating) of the antithrombotic polymeric compound 18 isselectively formed on the outer surface 3 a′ of the hollow fibermembrane 3. FIG. 2 shows an aspect where the coat (coating) of theantithrombotic polymeric compound 18 is formed on the outer surface 3 a′of the hollow fiber membrane used in the hollow fiber membraneoxygenator of an outside blood flow type. In the hollow fiber membraneof such an aspect, the outer surface 3 a′ side is in contact with theblood, and the oxygen-containing gas flows into an inner surface 3 c′side.

Note that “the antithrombotic polymeric compound coats the outsidesurface of the hollow fiber membrane” means that the coat (coating) ofthe antithrombotic polymeric compound is formed on the outer surface ofthe hollow fiber membrane (a surface on the side where the blood flows)or on the outer surface and the outer surface layer. On the other hand,“the antithrombotic polymeric compound coats the outer surface of thehollow fiber membrane” means that the coat (coating) of theantithrombotic polymeric compound is formed on the outer surface of thehollow fiber membrane (a surface on the side where the blood flows).Further, “the antithrombotic polymeric compound coats the outer surfacelayer of the hollow fiber membrane” means that the antithromboticpolymeric compound penetrates into a part of the outer surface layer ofthe hollow fiber membrane (in the vicinity of the outer surface of thefine holes) to form the coat (coating). The coat (coating) of theantithrombotic polymeric compound may be formed on at least a part ofthe blood contact portion (outer surface) of the hollow fiber membrane.From the viewpoint of the antithrombotic activity and biocompatibility(the suppression and prevention effects of adhesion and attachment ofthe platelets and the suppression and prevention effects of activationof the platelets), it is preferable that the coating be formed on theentire blood contact portion of the hollow fiber membrane (outersurface). That is, the antithrombotic polymeric compound preferablycoats the entire blood contact portion of the oxygenator (outersurface).

In the embodiment according to FIG. 2, the antithrombotic polymericcompound may exist on an internal layer 3 b or an inner surface layer 3c of the hollow fiber membrane 3, but it is preferable that nosubstantial material exist on the internal layer 3 b or the innersurface layer 3 c of the hollow fiber membrane 3. In the presentspecification, “no substantial antithrombotic polymeric compound existson the internal layer 3 b or the inner surface layer 3 c of the hollowfiber membrane 3” means that the penetration of the antithromboticpolymeric compound is not observed in the vicinity of the inside surfaceof the hollow fiber membrane (a surface on the side where theoxygen-containing gas flows). In the method for manufacturing anoxygenator according to the present invention, the coating is formed byapplying the colloidal solution of the antithrombotic polymer.Therefore, it is possible to achieve an aspect in which no substantialantithrombotic polymeric compound exists on the internal layer 3 b orthe inner surface layer 3 c of the hollow fiber membrane 3.

A hollow fiber membrane type oxygenator 1 according to the presentembodiment includes: a housing 2 having a blood inlet port 6 and a bloodoutlet port 7; a hollow fiber membrane bundle having a large number ofporous hollow fiber membranes 3 for gas exchange accommodated in thehousing 2; a pair of partition walls 4 and 5 liquid-tightly supportingboth end portions of the hollow fiber membrane bundle within the housing2; a blood chamber 12 formed between the inside surface of the housing 2and the partition walls 4 and 5, and the outside surfaces of the hollowfiber membranes 3; a gas chamber formed inside the hollow fibermembranes 3; and a gas inlet port 8 and a gas outlet port 9communicating with the gas chamber.

Specifically, the hollow fiber membrane type oxygenator 1 of the presentembodiment includes the tubular housing 2, an aggregate of the hollowfiber membranes 3 for gas exchange accommodated in the tubular housing2, and the partition walls 4 and 5 liquid-tightly retaining both endportions of the hollow fiber membranes 3 within the housing 2. Thetubular housing 2 is partitioned into the blood chamber 12 that is afirst fluid chamber and the gas chamber that is a second fluid chamber.The blood inlet port 6 and the blood outlet port 7 communicating withthe blood chamber 12 are provided in the tubular housing 2.

A cap-like gas inlet side header 10 having the gas inlet port 8 that isa second fluid inlet port communicating with the gas chamber that is theinner spaces of the hollow fiber membranes 3, is attached above thepartition walls 4 that are the end portion of the tubular housing 2. Agas inlet chamber 13 is formed of the outside surface of the partitionwalls 4 and the inside surface of the gas inlet side header 10. The gasinlet chamber 13 communicates with the gas chamber that is formed of theinner spaces of the hollow fiber membranes 3.

Similarly, a cap-like gas outlet side header 11 having a gas outlet port9 that is a second fluid outlet port communicating with the inner spacesof the hollow fiber membranes 3, is attached below the partition walls5. Therefore, a gas outlet chamber 14 is formed of the outside surfaceof the partition walls 5 and the inside surface of the gas outlet sideheader 11.

The hollow fiber membranes 3 are porous membranes made of a hydrophobicpolymer material. Membranes similar to hollow fiber membranes for use ina known oxygenator are used and are not particularly limited. The hollowfiber membranes (particularly, the inside surfaces of the hollow fibermembranes) are made of a hydrophobic polymer material, and thus theleakage of blood plasma components can be suppressed.

Here, an inner diameter of the hollow fiber membrane is not particularlylimited and is preferably 50 to 300 μm, more preferably 100 to 250 μm,and still more preferably 150 to 200 μm. An outer diameter of the hollowfiber membrane is not particularly limited and is preferably 100 to 400μm, more preferably 200 to 350 μm, and still more preferably 250 to 300μm. A wall thickness (membrane thickness) of the hollow fiber membraneis preferably 20 μm to 100 μm, more preferably 25 to 80 μm, still morepreferably 25 to 70 μm, and particularly preferably 25 to 60 μm. In thepresent specification, “the wall thickness (membrane thickness) of thehollow fiber membrane” means a wall thickness between the inner surfaceand the outer surface of the hollow fiber membrane, and is calculated byusing the expression: [(outer diameter of hollow fiber membrane)−(innerdiameter of hollow fiber membrane)]/2. Here, a lower limit of the wallthickness of the hollow fiber membrane is set as above, so that it ispossible to secure the sufficient strength of the hollow fibermembranes. Further, it is satisfactory in terms of labor and cost inmanufacturing, and is also preferable from the viewpoint of massproduction. Furthermore, porosity of the hollow fiber membrane ispreferably 5 to 90% by volume, more preferably 10 to 80% by volume, andparticularly preferably 30 to 60% by volume. A fine hole size of thehollow fiber membrane (i.e., a hole size of the opening portion of thehollow fiber) is not particularly limited and is preferably 10 nm to 5μm, more preferably 50 nm to 1 μm, and particularly preferably 50 nm to100 nm.

In the present specification, a diameter of an opening portion of ahollow fiber membrane” indicates an average diameter of the openingportion on a side (the outer surface side in the present embodiment)that is coated with the antithrombotic polymeric compound (may simply bereferred to as “fine hole” in the present specification). Further, anaverage diameter of the opening portion (may simply be referred to as“hole size” or “fine hole size” in the present specification) ismeasured by a method described below.

First, an SEM image of a side (the outer surface in the presentembodiment) of the hollow fiber membranes to be coated with theantithrombotic polymeric compound is captured using a scanning electronmicroscope (SEM). Next, the obtained SEM image is subjected to an imageprocess, the hole portion (opening portion) is set to white, the otherportions are inverted to black, and the number of pixels in the whiteportion is measured. A boundary level of binarization is an intermediatevalue of a difference between the whitest portion and the blackestportion.

Subsequently, the number of pixels of the hole displaying white (openingportion) is measured. A hole area is calculated based on the number ofpixels of the hole and a resolution (μm/pixel) of the SEM image obtainedas described above. From the obtained hole area, a diameter of each holeis calculated assuming the hole to be circular. A diameter of, forexample, 500 holes is extracted, which is a statistically significantand random number, and an arithmetic average thereof is set as anaverage diameter of the opening portion of the hollow fiber.

As a material used for the porous membranes, a material similar to amaterial used as the hollow fiber membranes in a known oxygenator can beused. Specific examples thereof include polyolefin resins such aspolypropylene and polyethylene, and hydrophobic polymer materials suchas polysulfone, polyacrylonitrile, polytetrafluoroethylene, andcellulose acetate. Among these, a polyolefin resin is preferably used,and polypropylene is more preferable. The method for manufacturinghollow fiber membranes is not particularly limited, and a known methodfor producing hollow fiber membranes can be applied similarly orappropriately modified and applied. For example, it is preferable thatmicro fine holes be formed on the walls of the hollow fiber membranesthrough a stretching method or a solid-liquid phase separation method.

As a material constituting the tubular housing 2, a material similar toa material used for a housing of a known oxygenator can be used.Specific examples thereof include hydrophobic synthetic resins such aspolycarbonate, acrylic-styrene copolymer, and acrylic-butylene-styrenecopolymer. A shape of the housing 2 is not particularly limited, and ispreferably cylindrical and transparent, for example. The inside thereofcan be easily confirmed by forming the housing to be transparent.

An accommodation amount of the hollow fiber membranes in the presentembodiment is not particularly limited, and an amount similarly to anamount for use in a known oxygenator can be applied. For example, about5,000 to 100,000 porous hollow fiber membranes 3 are accommodated inparallel in the housing 2 in an axial direction thereof. Further, boththe ends of the hollow fiber membranes 3 are respectively open towardsboth the ends of the housing 2, and the hollow fiber membranes 3 arefixed in a liquid-tight state by the partition walls 4 and 5. Thepartition walls 4 and 5 are formed by a potting agent such aspolyurethane or silicone rubber. A portion interposed between thepartition walls 4 and 5 in the housing 2 is divided into the gas chamberinside the hollow fiber membranes 3 and the blood chamber 12 outside thehollow fiber membranes 3.

In the present embodiment, the gas inlet side header 10 having the gasinlet port 8 and the gas outlet side header 11 having the gas outletport 9 are liquid-tightly attached to the housing 2. These headers maybe formed of any material, and can be formed of a hydrophobic syntheticresin used for the housing described above, for example. The header maybe attached by any method. For example, the header can be attached tothe housing 2 by fusion bonding using ultrasound waves, high frequencywaves, induction heating, and the like, by adhesion with an adhesive, orby mechanical engagement. In addition, the attachment may be performedby using a fastening ring (not shown). It is preferable that the entireblood contact portion of the hollow fiber membrane type oxygenator 1(the inside surface of the housing 2, the outside surfaces of the hollowfiber membranes 3) be formed of a hydrophobic material.

As shown in FIG. 2, the antithrombotic polymeric compound 18 coats atleast the outer surface 3 a′ (and optionally, the outer surface layer 3a; hereinafter the same applies) of the hollow fiber membrane 3 whichserves as the blood contact portion of the hollow fiber membrane typeoxygenator 1. As described above, it is preferable that no substantialantithrombotic polymeric compound exist on the internal layer 3 b or theinner surface layer 3 c of the hollow fiber membrane. In the case nosubstantial antithrombotic polymeric compound exists, hydrophobicproperties of the base material itself of the membrane are maintained asthey are on the internal layer 3 b or the inner surface layer 3 c of thehollow fiber membrane, and therefore the leakage of blood plasmacomponents can be effectively prevented. Particularly, it is preferablethat no substantial antithrombotic polymeric compound exist on both theinternal layer 3 b and the inner surface layer 3 c of the hollow fibermembrane. Further, the hollow fiber membrane 3 includes, in the center,a passage (lumen) 3 d forming the gas chamber. In addition, the hollowfiber membrane 3 includes an opening portion 3 e through which the outersurface 3 a′ and the inner surface 3 c′ thereof communicate with eachother. In the hollow fiber membrane having such a configuration, theblood comes into contact with the outer surface 3 a′ coated with theantithrombotic polymeric compound 18. Meanwhile, the oxygen-containinggas flows and contacts the inner surface 3 c′.

In the present embodiment, the coat (coating) of the antithromboticpolymeric compound is selectively formed on the outer surfaces of thehollow fiber membranes (outside flow type). For this reason, the blood(particularly, blood plasma components) is unlikely to or does notpenetrate into the inside of the fine holes of the hollow fibermembranes. Therefore, it is possible to effectively suppress or preventblood (particularly, blood plasma components) leakage from the hollowfiber membranes. Particularly, in a case where no substantialantithrombotic polymeric compound exists on the internal layers 3 b ofthe hollow fiber membranes and the inner surface layers 3 c of thehollow fiber membranes, the hydrophobic state of the material ismaintained on the internal layers 3 b of the hollow fiber membranes andthe inner surface layers 3 c of the hollow fiber membranes, andtherefore leakage of a large amount of blood (particularly, blood plasmacomponents) can be further effectively suppressed or prevented.Accordingly, in an oxygenator obtained by the method of the presentinvention, a high level of gas exchange capacity can be maintained for along period of time.

It is essential that the antithrombotic polymeric compound coatingaccording to the present embodiment be formed on the outer surfaces ofthe hollow fiber membranes of the oxygenator. The coating may be formedon another constituent member (for example, on the entire blood contactportion) in addition to the outer surfaces. In the case of having theconfiguration, adhesion, attachment, and activation of the platelets canbe further effectively suppressed or prevented in the entire bloodcontact portion of the oxygenator. In addition, since a contact angle ofthe blood contact surface decreases, this can facilitate a primingoperation. In this case, it is preferable that the antithromboticpolymeric compound coating according to the present invention be formedon the other constituent member in contact with the blood. Theantithrombotic polymeric compound does not coat a portion other than theblood contact portions of the hollow fiber membranes, or on anotherportion of the hollow fiber membranes (for example, a portion buried inthe partition walls). Such a portion is not in contact with the blood,and therefore, the antithrombotic polymeric compound not being coatedthereon does not cause a particular problem.

In addition, the oxygenator obtained by the method of the presentinvention may be a type shown in FIG. 3. FIG. 3 is a cross-sectionalview showing another embodiment of an oxygenator obtained by the methodof the present invention. Furthermore, FIG. 4 is a cross-sectional viewtaken along line A-A of FIG. 3.

In FIG. 3, an oxygenator (hollow fiber membrane oxygenator of an outsideblood flow type) 20 includes an inner tubular member 31 having a bloodcirculation opening 32 on a side surface thereof, a tubular hollow fibermembrane bundle 22 having the large number of porous hollow fibermembranes 3 for gas exchange and wound around an outside surface of theinner tubular member 31, a housing 23 accommodating the tubular hollowfiber membrane bundle 22 together with the inner tubular member 31,partition walls 25 and 26 fixing both end portions of the tubular hollowfiber membrane bundle 22 within the housing in a state where both theends of the hollow fiber membranes 3 are open, a blood inlet port 28 andblood outlet ports 29 a and 29 b communicating with a blood chamber 17formed in the housing 23, and a gas inlet port 24 and a gas outlet port27 communicating with the insides of the hollow fiber membranes 3.

In the oxygenator 20 of the present embodiment, as shown in FIG. 3 andFIG. 4, the housing 23 has an outer tubular member 33 accommodating theinner tubular member 31, and the tubular hollow fiber membrane bundle 22is accommodated between the inner tubular member 31 and the outertubular member 33. Further, the housing 23 has one of the blood inletport or the blood outlet port communicating with the inside of the innertubular member, and the other one of the blood inlet port or the bloodoutlet port communicating with the inside of the outer tubular member.

Specifically, in the oxygenator 20 of the present embodiment, thehousing 23 has an inner tubular body 35 that is accommodated in theouter tubular member 33 and the inner tubular member 31, and in which adistal end thereof is open in the inner tubular member 31. The bloodinlet port 28 is formed on one end (lower end) of the inner tubular body35, and the two blood outlet ports 29 a and 29 b extending outwards areformed on a side surface of the outer tubular member 33. There may beone or a plurality of the blood outlet ports.

The tubular hollow fiber membrane bundle 22 is wound around the outsidesurface of the inner tubular member 31. That is, the inner tubularmember 31 is a core of the tubular hollow fiber membrane bundle 22. Adistal end portion of the inner tubular body 35 accommodated inside theinner tubular member 31 is open in the vicinity of the first partitionwalls 25. In addition, the blood inlet port 28 is formed on a protrudinglower end portion by the inner tubular member 31.

Each of the inner tubular body 35, the inner tubular member 31 where thehollow fiber membrane bundle 22 is wound around the outside surfacethereof, and the outer tubular member 33 is arranged almostconcentrically. One end (upper end) of the inner tubular member 31 wherethe hollow fiber membrane bundle 22 is wound around the outside surfacethereof, and one end (upper end) of the outer tubular member 33 maintainthe concentric positional relationship between each other by the firstpartition walls 25, and are in the liquid-tight state where a spaceformed between the inside of the inner tubular member 31 and the innertubular body 35, and a space formed between the outside surfaces of thehollow fiber membrane bundle 22 and the outer tubular member 33 do notcommunicate with the outside.

Further, a portion that is in a slightly upper position than the bloodinlet port 28 of the inner tubular body 35, the other end (lower end) ofthe inner tubular member 31 where the hollow fiber membrane bundle 22 iswound around the outside surface thereof, and the other end (lower end)of the outer tubular member 33 maintain the concentric positionalrelationship between each other by the second partition walls 26. Theabove components are in a liquid-tight state where a space formedbetween the inside of the inner tubular member 31 and the inner tubularbody 35, and a space formed between the outside surfaces of the hollowfiber membrane bundle 22 and the outer tubular member 33 do notcommunicate with the outside. Furthermore, the partition walls 25 and 26are formed by a potting agent such as polyurethane or silicone rubber.

Therefore, the oxygenator 20 of the present embodiment includes a bloodinlet portion 17 a formed by the inside of the inner tubular body 35, afirst blood chamber 17 b that is a substantially tubular space formedbetween the inner tubular body 35 and the inner tubular member 31, and asecond blood chamber 17 c that is a substantially tubular space formedbetween the hollow fiber membrane bundle 22 and the outer tubular member33, and thereby the blood chamber 17 is formed.

The blood flowing from the blood inlet port 28 flows into the bloodinlet portion 17 a, moves up in the inner tubular body 35 (blood inletportion 17 a), flows out from an upper end 35 a (opening end) of theinner tubular body 35, flows into the first blood chamber 17 b, passesthrough an opening 32 formed in the inner tubular member 31, comes intocontact with the hollow fiber membranes, and after gas exchange, flowsinto the second blood chamber 17 c, and flows out from the blood outletports 29 a and 29 b.

Further, a gas inlet member 41 having the gas inlet port 24 is fixed toone end of the outer tubular member 33, and similarly, a gas outletmember 42 having the gas outlet port 27 is fixed to the other end of theouter tubular member 33. The blood inlet port 28 of the inner tubularbody 35 protrudes through the gas outlet member 42.

The outer tubular member 33 is not particularly limited, and a memberhaving a tubular body, a polygonal tube, an elliptical shape in thecross section, and the like can be used. The member is preferably thetubular body. Further, an inner diameter of the outer tubular member isnot particularly limited, and the inner diameter of the outer tubularmember can be a diameter similar to a diameter for use in a knownoxygenator. It is suitable that the diameter be approximately 32 to 164mm. Furthermore, an effective length of the outer tubular member (theportion of the length of the outer tubular member that is not buried inthe partition walls) is not particularly limited, and the length can bean effective length similar to the effective length of the outer tubularmember for use in a known oxygenator. It is suitable that the effectivelength of the outer tubular member be approximately 10 to 730 mm.

Furthermore, a shape of the inner tubular member 31 is not particularlylimited, and for example, a member having a tubular body, a polygonaltube, an elliptical shape in the cross section, and the like can beused. The member is preferably the tubular body. Furthermore, an outerdiameter of the inner tubular member is not particularly limited, andthe outer diameter can be an outer diameter similar to the outerdiameter of the inner tubular member for use in a known oxygenator. Itis suitable that the outer diameter be approximately 20 to 100 mm.Furthermore, the effective length of the inner tubular member (theportion of the length of the inner tubular member that is not buried inthe partition walls) is not particularly limited, and the length can bean effective length similar to the effective length of the inner tubularmember for use in a known oxygenator. It is suitable that the effectivelength of the inner tubular member be approximately 10 to 730 mm.

The inner tubular member 31 includes a large number of blood circulationopenings 32 on the side surface thereof. Regarding a size of the opening32, it is preferable that a total area be large as long as the requiredstrength of the tubular member is maintained. As shown in FIG. 5 that isa front view, FIG. 6 that is a central longitudinal cross-sectional viewof FIG. 5, and FIG. 7 that is a cross-sectional view taken along lineB-B of FIG. 5, as a tubular member satisfying such conditions, forexample, it is suitable to use a tubular member having a plurality ofsets (8 sets for periphery, in the drawings) of circularly arrangedopenings in which a plurality of the openings 32 is provided on an outerperipheral surface of the tubular member at an equal angle and interval(for example, each set includes 4 to 24 openings, in the drawings, 8openings are arranged in a longitudinal direction) and which is providedin an axial direction of the tubular member at an equal interval.Further, an opening shape may be a circle, a polygon, an ellipse, andthe like, but an oval shape is suitable as shown in FIG. 5.

In addition, a shape of the inner tubular body 35 is not particularlylimited, and for example, a body having a tubular body, a polygonaltube, an elliptical shape in the cross section, and the like can beused. The member is preferably the tubular body. Further, a distancebetween a distal end opening of the inner tubular body 35 and the firstpartition walls 25 is not particularly limited, and a distance similarto a distance for use in a known oxygenator can be applied. It issuitable that the distance be approximately 20 to 50 mm. Furthermore, aninner diameter of the inner tubular body 35 is not particularly limited,and the inner diameter can be an inner diameter similar to an innerdiameter of the inner tubular body for use in a known oxygenator. It issuitable that the inner diameter of the inner tubular body beapproximately 10 to 30 mm.

A thickness of the tubular hollow fiber membrane bundle 22 is notparticularly limited, and the thickness can be a thickness similar to athickness of the tubular hollow fiber membrane bundle for use in a knownoxygenator. It is preferable that the thickness be 5 to 35 mm,particularly 10 mm to 28 mm. Further, a filling rate of the hollow fibermembranes with respect to the tubular space formed by a space betweenthe outside surface of the tubular hollow fiber membrane bundle 22 andthe inside surface is not particularly limited, and a filling rate foruse in a known oxygenator can be applied similarly. The filling rate ispreferably 40% to 85%, particularly 45% to 80%. Furthermore, an outerdiameter of the hollow fiber membrane bundle 22 can be an outer diametersimilar to an outer diameter of the hollow fiber membrane bundle used ina known oxygenator. The outer diameter of the hollow fiber membranebundle is preferably 30 to 170 mm, particularly 70 to 130 mm. As a gasexchange membrane, the membrane described above is used.

The hollow fiber membrane bundle 22 can be formed by winding the hollowfiber membranes around the inner tubular member 31, specifically, usingthe inner tubular member 31 as a core, forming a hollow fiber membranebobbin, fixing both ends of the formed hollow fiber membrane bobbin bythe partition walls, and then cutting both the ends of the hollow fibermembrane bobbin together with the inner tubular member 31 that is acore. The hollow fiber membranes become open on the outside surface ofthe partition walls by this cutting. A method for forming hollow fibermembranes is not limited to the above method, and any known method forforming hollow fiber membranes may be used similarly or appropriatelymodified for use.

Particularly, it is preferable that one or a plurality of the hollowfiber membranes be wound around the inner tubular member 31substantially in parallel at the same time such that adjacent hollowfiber membranes have a substantially constant interval. Therefore, blooddrift can be suppressed more effectively. Further, a distance betweenthe hollow fiber membrane and an adjacent hollow fiber membrane is notlimited to the following, but the distance is preferably 1/10 to 1/1 ofthe outer diameter of the hollow fiber membranes. Furthermore, thedistance between the hollow fiber membrane and an adjacent hollow fibermembrane is preferably 30 to 200 μm.

Furthermore, preferably, the hollow fiber membrane bundle 22 is formedby one or a plurality (preferably, 2 to 16 membranes) of the hollowfiber membranes being wound around the inner tubular member 31 at thesame time such that all adjacent hollow fiber membranes have asubstantially constant interval, and the hollow fiber membrane bundle 22is formed by the hollow fiber membranes being wound around the innertubular member 31 according to movement of a rotator for rotating theinner tubular member 31 and a winder for interweaving the hollow fibermembranes under the condition in Expression (1) when winding the hollowfiber membranes around the inner tubular member:traverse[mm/lot]×n(integer)=traverse amplitude×2±(outer diameter offiber+interval)×the number of windings

It is possible to further reduce the formation of blood drift by settingthe condition as above. The variable n represents a ratio between thenumber of rotations of the rotator for winding and the number ofreciprocations of the winder at this time, and is not particularlylimited, but is usually 1 to 5, preferably 2 to 4.

Further, also in the hollow fiber membrane type oxygenator 20, theantithrombotic polymeric compound 18 according to the present inventioncoats at least the outer surface 3 a′ (and optionally, the outer surfacelayer 3 a) of the hollow fiber membrane 3 of this hollow fiber membranetype oxygenator 1, as shown in FIG. 2. Here, the antithromboticpolymeric compound may exist on the internal layer 3 b or the innersurface layer 3 c of the hollow fiber membrane 3, but it is preferablethat no substantial antithrombotic polymeric compound exist on theinternal layer 3 b or the inner surface layer 3 c of the hollow fibermembrane. Further, the hollow fiber membrane 3 includes, in the center,a passage (lumen) 3 d forming the gas chamber. In addition, the hollowfiber membrane 3 includes an opening portion 3 e through which the outersurface 3 a′ and the inner surface 3 c′ thereof communicate with eachother. Here, the dimensions of the hollow fiber membrane (innerdiameter, outer diameter, wall thickness, porosity, size of fine holes,and the like) are not particularly limited, but the same aspect asdescribed in FIG. 1 above can be adopted.

In the oxygenator 20 according to the present embodiment, the hollowfiber membranes 3 have a bobbin shape in which membranes are in contactwith each other and overlapped many times. In the present embodiment,the antithrombotic polymeric compound coating is selectively anduniformly formed on the outer surfaces 3 a′ of the hollow fibermembranes. With such a configuration, the leakage of blood(particularly, blood plasma components) to the inner surface layers 3 cof the hollow fiber membranes can be suppressed or prevented. That is,the leakage of blood (particularly, blood plasma components) can beeffectively suppressed or prevented by the antithrombotic polymericcompound selectively coating the outer surfaces 3 a′ (and optionally,the outer surface layers 3 a) of the hollow fiber membranes 3, whichserve as the blood contact portion. Particularly, in a case where nosubstantial antithrombotic polymeric compound according to the presentinvention exists on the internal layers 3 b and the inner surface layers3 c of the hollow fiber membranes 3, the hydrophobic state of thematerial is maintained on the internal layers 3 b and the inner surfacelayers 3 c of the hollow fiber membranes, and therefore a large amountof blood (particularly, blood plasma components) leakage can be furthereffectively suppressed or prevented. In the present embodiment, theblood flow path is complicated and has many narrow portions, which isexcellent for the gas exchange capacity, but the adhesion, attachment,and activation of the platelets may deteriorate compared to theoxygenator of an outside blood flow type which is not a bobbin type.However, as described above, since the antithrombotic polymeric compoundcoating is uniform, the adhesion, attachment, and activation of theplatelets in the blood contact portions of the hollow fiber membranesoccur less. Furthermore, separation of the coating from the hollow fibermembranes (particularly, a portion where coating is uneven) can besuppressed or prevented.

In addition, it is essential that the antithrombotic polymeric compoundcoating according to the present embodiment be formed on the outersurfaces of the hollow fiber membranes of the oxygenator. The coatingmay be formed on another constituent member (for example, on the entireblood contact portion) in addition to the outer surfaces. In the case ofhaving the configuration, adhesion, attachment, and activation of theplatelets can be further effectively suppressed or prevented in theentire blood contact portion of the oxygenator. In addition, since acontact angle of the blood contact surface decreases, this canfacilitate a priming operation. In this case, it is preferable that theantithrombotic polymeric compound coating be formed on the otherconstituent member in contact with the blood. The antithromboticpolymeric compound does not coat a portion other than the blood contactportions of the hollow fiber membranes, or on another portion of thehollow fiber membranes (for example, a portion buried in the partitionwalls, and a contact portion of the hollow fiber). Such a portion is notin contact with the blood, and therefore, the antithrombotic polymericcompound not being coated thereon does not cause a particular problem.

[Method for Manufacturing Oxygenator]

The method for manufacturing an oxygenator according to the presentinvention includes a method for manufacturing an oxygenator having ahollow fiber membrane bundle with a plurality of porous hollow fibermembranes for gas exchange which have outer surfaces, inner surfacesforming lumens, opening portions through which the outer surfacescommunicate with the inner surfaces in a housing, a blood flow pathwhich is outside of the hollow fiber membrane bundle in the housing, ablood inlet port in an upper position of the blood flow path, and ablood outlet port in a lower position of the blood flow path, the methodincluding: filling the blood flow path with a colloidal solutioncontaining an antithrombotic polymeric compound; and moving(circulating) the colloid solution between the blood inlet port and theblood outlet port.

In the method of the present invention, a solution (colloidal solution)containing an antithrombotic polymeric compound is first prepared. Then,the blood flow path is filled with the colloidal solution, and the outersurface of the hollow fiber membrane is coated while moving thecolloidal solution. Hereinafter, (1) a step of preparing a colloidalsolution and (2) a step of coating (covering) the colloidal solutionwill be described respectively.

(1) Step of Preparing Colloidal Solution

In this step, a colloidal solution for coating the outer surface of thehollow fiber membrane is prepared. As described above, the colloidalsolution used in the method according to the present invention containsan antithrombotic polymeric compound.

First, the antithrombotic polymeric compound used in preparing thecolloidal solution according to the present invention will be described.

(Antithrombotic Polymeric Compound and Method for Manufacturing Thereof)

The antithrombotic polymeric compound used in the present invention is acompound that imparts antithrombotic activity to an oxygenator whenbeing applied to the hollow fiber membranes. Further, “theantithrombotic activity” refers to a property of reducing coagulation ofblood on a surface that comes into contact with blood.

The antithrombotic polymeric compound can be used without particularlimitation as long as it has antithrombotic activity andbiocompatibility. Among them, from the viewpoint of the excellentcharacteristics, the antithrombotic polymeric compound preferably has astructural unit derived from alkoxyalkyl(meth)acrylate represented bythe following Formula (I):

In the formula, R³ represents a hydrogen atom or a methyl group, R¹represents an alkylene group having 1 to 4 carbon atoms, and R²represents an alkyl group having 1 to 4 carbon atoms.

The compound having a structural unit represented by the Formula (I) isexcellent in the antithrombotic activity and biocompatibility (thesuppression and prevention effects of adhesion and attachment of theplatelets and the suppression and prevention effects of activation ofthe platelets), particularly excellent in the suppression and preventioneffects of activation of the platelets. Therefore, it is possible tomanufacture an oxygenator excellent in the antithrombotic activity andbiocompatibility (the suppression and prevention effects of adhesion andattachment of the platelets and the suppression and prevention effectsof activation of the platelets), particularly excellent in thesuppression and prevention effects of activation of the platelets byusing the compound having the structural unit.

In the present specification, “(meth)acrylate” means “acrylate and/ormethacrylate”. That is, “alkoxyalkyl(meth)acrylate” includes all casesof only alkoxyalkyl acrylate, only alkoxyalkyl methacrylate, andalkoxyalkyl acrylate and alkoxyalkyl methacrylate.

In the Formula (I), R¹ represents an alkylene group having 1 to 4 carbonatoms. Here, the alkylene group having 1 to 4 carbon atoms is notparticularly limited, and includes a linear or branched alkylene groupof methylene group, an ethylene group, a trimethylene group, atetramethylene group, and a propylene group. Among these, an ethylenegroup and a propylene group are preferable, and in consideration offurther enhanced effects of antithrombotic activity andbiocompatibility, an ethylene group is particularly preferable. R²represents an alkyl group having 1 to 4 carbon atoms. Here, the alkylgroup having 1 to 4 carbon atoms is not particularly limited, andinclude a linear or branched alkyl group of a methyl group, an ethylgroup, a propyl group, an isopropyl group, a butyl group, an isobutylgroup, a sec-butyl group, and a tert-butyl group. Among these, a methylgroup and an ethyl group are preferable, and in consideration of furtherenhanced effects of antithrombotic activity and biocompatibility, amethyl group is particularly preferable. R³ represents a hydrogen atomor a methyl group. Note that in a case where the antithromboticpolymeric compound according to the present invention has two or more ofstructural units derived from alkoxyalkyl(meth)acrylate, each structuralunit may be the same as or different from each other.

Specific examples of alkoxyalkyl(meth)acrylate include methoxymethylacrylate, methoxyethyl acrylate, methoxypropyl acrylate, ethoxymethylacrylate, ethoxyethyl acrylate, ethoxypropyl acrylate, ethoxybutylacrylate, propoxymethyl acrylate, butoxyethyl acrylate, methoxybutylacrylate, methoxymethyl methacrylate, methoxyethyl methacrylate,ethoxymethyl methacrylate, ethoxyethyl methacrylate, propoxymethylmethacrylate, butoxyethyl methacrylate, and the like. Among these, fromthe viewpoint of further enhanced effects of antithrombotic activity andbiocompatibility, methoxyethyl(meth)acrylate and methoxybutyl acrylateare preferable, and methoxyethyl acrylate (MEA) is particularlypreferable. That is, the antithrombotic polymeric compound according tothe present invention is preferably polymethoxyethyl acrylate (PMEA).The alkoxyalkyl(meth)acrylate may be used singly, or in mixture of twoor more kinds thereof.

The antithrombotic polymeric compound according to the present inventionpreferably has a structural unit derived from alkoxyalkyl(meth)acrylate,and may be a polymer (homopolymer) having one or two or more ofstructural units derived from alkoxyalkyl(meth)acrylate, or may be apolymer (copolymer) having one or two or more of structural unitsderived from alkoxyalkyl(meth)acrylate, and one or two or more ofstructural units (other structural units) derived from a monomercopolymerizable with the alkoxyalkyl(meth)acrylate. In a case where theantithrombotic polymeric compound according to the present invention isconfigured to include two or more structural units, the structure of thepolymer (copolymer) is not particularly limited, and may be any one of arandom copolymer, an alternating copolymer, a periodic copolymer, and ablock copolymer. In addition, the end of the polymer is not particularlylimited and is appropriately determined according to the type of rawmaterial being used, and is usually a hydrogen atom.

Here, in a case where the antithrombotic polymeric compound according tothe present invention has structural units other than the structuralunits derived from alkoxyalkyl(meth)acrylate, a monomer copolymerizablewith the alkoxyalkyl(meth)acrylate (copolymerizable monomer) is notparticularly limited. Examples thereof include methyl acrylate, ethylacrylate, propyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, methylmethacrylate, ethyl methacrylate, propyl methacrylate, butylmethacrylate, 2-ethylhexyl methacrylate, hexyl acrylate, hexylmethacrylate, ethylene, propylene, acrylamide, N,N-dimethylacrylamide,N,N-diethylacrylamide, aminomethyl acrylate, aminoethyl acrylate,aminoisopropyl acrylate, diaminomethyl acrylate, diaminoethyl acrylate,diaminobutyl acrylate, methacrylamide, N,N-dimethylmethacrylamide,N,N-diethyl methacrylamide, aminomethyl methacrylate, aminoethylmethacrylate, diaminomethyl methacrylate, diaminoethyl methacrylate, andthe like. Among these, as a copolymerizable monomer, a monomer nothaving a hydroxyl group or a cationic group in the molecule ispreferable. The copolymer may be any of a random copolymer, a blockcopolymer, and a graft copolymer, and can be synthesized by a knownmethod such as radical polymerization, ionic polymerization, orpolymerization using a macromer. Here, in all structural units of thecopolymer, a ratio of the structural units derived from acopolymerizable monomer is not particularly limited, but inconsideration of antithrombotic activity, biocompatibility, and thelike, the structural units derived from a copolymerizable monomer (theother structural units) are more than 0% by mole and 50% by mole or lesswith respect to all structural units of the copolymer. If the units aremore than 50% by mole, there is a possibility that the effect ofalkoxyalkyl(meth)acrylate deteriorates.

Here, a weight average molecular weight of the antithrombotic polymericcompound is not particularly limited, and is preferably 80,000 or more.In the method for manufacturing an oxygenator according to the presentinvention, the antithrombotic polymeric compound in the form of thecolloidal solution is applied to the outer surface or inner surface ofthe hollow fiber membrane. Therefore, the weight average molecularweight of the antithrombotic polymeric compound is preferably less than800,000 from the viewpoint that a desired colloidal solution can beeasily prepared. In a case where the weight average molecular weight iswithin the above range, it is possible to prevent aggregation orprecipitation of the compound in the solution containing theantithrombotic polymeric compound and to prepare a stable colloidalsolution. Further, the weight average molecular weight of theantithrombotic polymeric compound is preferably more than 200,000 andless than 800,000, more preferably 210,000 to 600,000, still morepreferably 220,000 to 500,000, and particularly preferably 230,000 to450,000.

In the present specification, the “weight average molecular weight” is aweight in which a value measured by gel permeation chromatography (GPC)using polystyrene as a standard substance and tetrahydrofuran (THF) as amobile phase, is adopted. Specifically, the polymer to be analyzed isdissolved in THF to prepare a 1 mg/ml solution. Regarding the polymersolution thus prepared, a Shodex GPC column LF-804 (manufactured byShowa Denko K.K.) is attached to a GPC system LC-20 (manufactured byShimadzu Corporation), THF is allowed to flow as a mobile phase, andpolystyrene is used as a standard substance to measure GPC of thepolymer to be analyzed. After preparing a calibration curve withstandard polystyrene, the weight average molecular weight of the polymerto be analyzed is calculated based on this curve.

The content of a polymer having a relatively low molecular weight in thecoating can be reduced by increasing the molecular weight of theantithrombotic polymeric compound. As a result, the effects ofsuppressing or preventing the polymer having a relatively low molecularweight from being eluted into blood is obtained. Therefore, in a casewhere the weight average molecular weight of the antithromboticpolymeric compound is within the above range, elution of the coating(particularly, a polymer having a low molecular weight) into blood canbe further effectively suppressed or prevented. Further, it is alsopreferable from the viewpoint of antithrombotic activity andbiocompatibility. Furthermore, in the present specification, “thepolymer having a low molecular weight” means a polymer having a weightaverage molecular weight of less than 60,000. Note that the method formeasuring the weight average molecular weight is as described above.

Further, the antithrombotic polymeric compound having a structural unitderived from alkoxyalkyl(meth)acrylate represented by the Formula (I)can be produced by a known method. Specifically, a method is preferablyused, in which alkoxyalkyl(meth)acrylate represented by the followingFormula (II):

and one or two or more monomers (copolymerizable monomer)copolymerizable with the above alkoxyalkyl(meth)acrylate added ifnecessary are stirred in a polymerization solvent together with apolymerization initiator to prepare a monomer solution, and the abovemonomer solution is heated, whereby alkoxyalkyl(meth)acrylate oralkoxyalkyl(meth)acrylate and a copolymerizable monomer added ifnecessary are (co)polymerized. In the Formula (II), substituents R¹, R²,and R³ are the same as those defined in the Formula (I), and thusdescription thereof is omitted.

The polymerization solvent that can be used in the preparation of themonomer solution is not particularly limited as long as it is a solventcapable of dissolving the alkoxyalkyl(meth)acrylate of the Formula (II)and a copolymerizable monomer added if necessary. Examples thereofinclude water, alcohols such as methanol, ethanol, propanol, andisopropanol; aqueous solvents such as polyethylene glycols; aromaticsolvents such as toluene, xylene and tetralin; halogenated solvents suchas chloroform, dichloroethane, chlorobenzene, dichlorobenzene,trichlorobenzene; and the like. Among these, in consideration ofalkoxyalkyl(meth)acrylate being easily dissolved and the polymer thathas the above weight average molecular weight being easily obtained,methanol is preferable.

A monomer concentration in the monomer solution is not particularlylimited, but the weight average molecular weight of the antithromboticpolymeric compound obtained can be increased by setting theconcentration relatively high. For this reason, in consideration of thepolymer that has the weight average molecular weight being easilyobtained, and the like, the monomer concentration in the monomersolution is preferably less than 50% by mass, and more preferably 15% bymass or more and less than 50% by mass. Further, the monomerconcentration in the monomer solution is preferably 20% by mass or moreand 48% by mass or less, and particularly preferably 25% by mass or moreand 45% by mass or less. In a case of using two or more of monomers, themonomer concentration means a total concentration of these monomers.

The polymerization initiator is not particularly limited, and a knowninitiator may be used. The initiator is a radical polymerizationinitiator in terms of being excellent in polymerization stability, andexamples thereof include persulfates such as potassium persulfate (KPS),sodium persulfate and ammonium persulfate; peroxides such as hydrogenperoxide, t-butyl peroxide and methyl ethyl ketone peroxide; and azocompounds such as azobisisobutyronitrile (AIBN),2,2′-azobis(4-methoxy-2,4-dimethylvaleronitrile),2,2′-azobis(2,4-dimethylvaleronitrile),2,2′-azobis[2-(2-imidazolin-2-yl)propane]dihydrochloride,2,2′-azobis[2-(2-imidazolin-2-yl)propane]disulfate dihydrate,2,2′-azobis(2-methylpropionamidine)dihydrochloride,2,2′-azobis[N-(2-carboxyethyl)-2-methylpropionamidine)]hydrate,3-hydroxy-1,1-dimethylbutyl peroxyneodecanoate, α-cumylperoxyneodecanoate, 1,1,3,3-tetrabutyl peroxyneodecanoate, t-butylperoxyneodecanoate, t-butyl peroxyneoheptanoate, t-butyl peroxypivalate,t-amyl peroxyneodecanoate, t-amyl peroxypivalate, di(2-ethylhexyl)peroxydicarbonate, di(secondary butyl)peroxydicarbonate, andazobiscyanovaleric acid. For example, a reducing agent such as sodiumsulfite, sodium hydrogen sulfite or ascorbic acid may be used incombination with the radical polymerization initiators as a redox typeinitiator. A blending amount of the polymerization initiators ispreferably 0.0001% to 1% by mole, more preferably 0.001% to 0.8% bymole, and particularly preferably 0.01% to 0.5% by mole with respect toa total amount of the monomer (alkoxyalkyl(meth)acrylate and acopolymerizable monomer added if necessary; hereinafter the sameapplies). Alternatively, the blending amount of the polymerizationinitiators is preferably 0.005 to 2 parts by mass, and more preferably0.05 to 0.5 parts by mass with respect to 100 parts by mass of monomer(a total mass in a case of using a plurality of types of monomers). Withsuch a blending amount of the polymerization initiators, the polymerhaving a desired weight average molecular weight can be more efficientlyproduced.

The polymerization initiator may be directly mixed with the monomers andthe polymerization solvent. The initiator in a solution state obtainedby the initiator dissolved in another solvent in advance, may bedirectly mixed with the monomers and the polymerization solvent. In thelatter case, the solvent is not particularly limited, as long as thepolymerization initiator can be dissolved in the solvent, and can be,for example, a solvent similar to the above polymerization solvent.Further, the solvent may be the same as or different from the abovepolymerization solvent, but is preferably a solvent that is the same asthe above polymerization solvent in consideration of the ease of controlof polymerization. Furthermore, in this case, a concentration of thepolymerization initiator in the solvent is not particularly limited, butan addition amount of the polymerization initiator is preferably 0.1 to10 parts by mass, more preferably, 0.15 to 5 parts by mass, still morepreferably 0.2 to 1.8 parts by mass with respect to 100 parts by mass ofthe solvent in consideration of the ease of mixing, and the like.

Next, the above monomer solution is heated, and thusalkoxyalkyl(meth)acrylate or alkoxyalkyl(meth)acrylate and the othermonomer are (co)polymerized. Here, as a polymerization method, forexample, a known polymerization method such as radical polymerization,anionic polymerization, and cationic polymerization can be adopted, andradical polymerization which facilitates production is preferably used.

Polymerization conditions are not particularly limited, as long as theabove monomers (alkoxyalkyl(meth)acrylate or alkoxyalkyl(meth)acrylateand the copolymerizable monomer) can be polymerized under theconditions. Specifically, the polymerization temperature is preferably30° C. to 60° C., and more preferably 40° C. to 55° C. Further, thepolymerization time is preferably 1 to 24 hours, and more preferably 3to 12 hours. Under such conditions, a polymer having a high molecularweight as described above can be further efficiently produced. Inaddition, it is possible to effectively suppress or prevent gelation inthe polymerization process and to achieve high production efficiency.

In addition, a chain transfer agent, a polymerization rate-adjustingagent, a surfactant, and other additives may be appropriately usedduring polymerization if necessary.

An atmosphere under which the polymerization reaction is carried out isnot particularly limited, and the reaction may be carried out under anair atmosphere, an inert gas atmosphere such as nitrogen gas or argongas, and the like. In addition, during the polymerization reaction, thereaction solution may be stirred.

The polymer after polymerization can be purified by a generalpurification method such as a reprecipitation method, a dialysis method,an ultrafiltration method or an extraction method. For the reason that a(co)polymer suitable for preparing the colloidal solution can beobtained, it is preferable to perform purification by a reprecipitationmethod among the above. Ethanol is preferably used as a poor solventused for performing reprecipitation.

The purified polymer can be dried by an arbitrary method such as freezedrying, reduced pressure drying, spray drying or heat drying, but freezedrying or reduced pressure drying is preferable from the viewpoint thatthe influence on the physical properties of the polymer is small.

Subsequently, a method for preparing a colloidal solution according tothe present invention will be described.

[Preparation of Colloidal Solution]

A solvent used in preparation of the antithrombotic polymericcompound-containing solution (colloidal solution) is not particularlylimited, as long as it can appropriately disperse the antithromboticpolymeric compound to prepare the colloidal solution. Preferably, thesolvent contains water to further effectively reduce or prevent thepenetration of the colloidal solution to the outer surfaces or the innersurfaces of the fine holes of the hollow fiber membranes (a surface onthe side where the oxygen-containing gas flows). Here, water ispreferably pure water, ion exchange water or distilled water, and amongthese, pure water (RO water) purified by a reverse osmosis membrane ispreferable.

A solvent other than water, which is used in preparation of thecolloidal solution, is not particularly limited, but is preferablymethanol or acetone in consideration of further ease of controllingdispersibility of the antithrombotic polymeric compound, and the like.The above solvent other than water may be used singly, or in mixture oftwo or more kinds thereof. Among these, in consideration of further easeof controlling dispersibility of the antithrombotic polymeric compound,and the like, the solvent is preferably methanol. That is, the solventpreferably contains water and methanol. Here, a mixing ratio of waterand methanol is not particularly limited. In consideration ofdispersibility of the antithrombotic polymeric compound and further easeof controlling an average particle size of the colloid particles, themixing ratio (mass ratio) of water:methanol is preferably 6:1 to 32:1,and more preferably 10:1 to 30:1. That is, the solvent preferablycontains water and methanol in the mixing ratio (mass ratio) of 6:1 to32:1, and more preferably contains water and methanol in the mixingratio (mass ratio) of 10:1 to 30:1.

As described above, when preparing the colloidal solution by using amixed solvent of water and a solvent other than water, the order ofadding the solvent (for example, water and methanol) and theantithrombotic polymeric compound is not particularly limited. It ispreferable to prepare the colloidal solution in the following order.That is, preferably, the antithrombotic polymeric compound is added to asolvent other than water (preferably, methanol) to prepare theantithrombotic polymeric compound-containing solution, and then thecolloidal solution is prepared by a method of adding the antithromboticpolymeric compound-containing solution to water. The antithromboticpolymeric compound is easily dispersed by such a method. Further, theabove method has an advantage that colloid particles having a uniformparticle size can be formed, and a uniform coating can be easily formed.

In the above method, an addition rate of the antithrombotic polymericcompound-containing solution to water is not particularly limited, butit is preferable to add the antithrombotic polymeric compound-containingsolution to water at an addition rate of 10 to 10,000 g/min.

Stirring time and stirring temperature in preparation of the colloidalsolution are not particularly limited. From the viewpoint of forming thecolloid particles having a uniform particle size and ease of dispersingthe colloid particles uniformly, it is preferable to perform stirringfor 1 to 30 minutes, and is more preferable to perform stirring for 5 to15 minutes, after addition of the antithrombotic polymeric compound towater. Further, the stirring temperature is preferably 10° C. to 40° C.,and more preferably from 20° C. to 30° C.

A concentration of the antithrombotic polymeric compound in thecolloidal solution is not particularly limited. From the viewpoint ofease of increasing the coating amount, the concentration is preferably0.005% by mass or more. Further, from the above viewpoint, the colloidalsolution contains the antithrombotic polymeric compound, preferably at aconcentration of 0.01% by mass or more, more preferably at aconcentration of 0.03% by mass or more, and particularly preferably at aconcentration of 0.04% by mass or more. On the other hand, an upperlimit of a concentration of the antithrombotic polymeric compound in thecolloidal solution is not particularly limited. In consideration of easeof forming the coating and the effect of reducing coating unevenness,the concentration is preferably 0.3% by mass or less, and morepreferably 0.2% by mass or less. Furthermore, in such a range, adecrease in gas exchange capacity due to an excessively thick coating ofthe antithrombotic polymeric compound is also suppressed.

(2) Step of Colloidal Solution Coating (Applying)

Next, the outer surfaces of the hollow fiber membranes are coated withthe colloidal solution prepared in the above manner. Specifically, afterassembling an oxygenator (for example, an oxygenator having the samestructure as that of FIG. 1 or FIG. 3), the blood flow path is filledwith the colloidal solution prepared in the above step (1), and thecolloidal solution is moved (e.g., circulated) between the blood inletport and the blood outlet port, whereby the outer surfaces of the hollowfiber membranes are coated with the antithrombotic polymeric compound.

Here, a method of moving the colloidal solution between the blood inletport and the blood outlet port is not particularly limited, and examplesthereof include a method of circulating the colloidal solution into theblood flow path of the oxygenator and a method of moving the colloidalsolution back and forth (i.e., a reciprocating motion) between the bloodinlet port and the blood outlet port. Among these, the method of movingthe colloidal solution back and forth between the blood inlet port andthe blood outlet port is preferable from the viewpoint of equipmentcost.

The method of circulating the colloidal solution into the blood flowpath of the oxygenator is not particularly limited as long as it is amethod in which the colloidal solution can be circulated. For example, aroller pump is used to circulate the colloidal solution to the bloodflow path of the oxygenator at a constant flow rate. In this case, aflow rate of the colloidal solution in the blood flow path is preferably0.1 L/min or more, more preferably 1 L/min or more, and still morepreferably 3 L/min or more. When the flow rate is within this range, thetime required for the coating step can be reduced. Further, the flowrate of the colloidal solution in the blood flow path is preferably 10L/min or less, more preferably 8 L/min or less, and still morepreferably 5 L/min or less. When the flow rate is within this range, theroller pump can be used, so this is preferable. Circulation time of thecolloidal solution in the blood flow path is not particularly limited,and the circulation time can be appropriately adjusted according to theflow rate. From the viewpoint of the time required for the coating stepand the balance of the coating amount, the circulation time of thecolloidal solution circulating in the blood flow path is preferably 1minute or more and 1 hour or less, more preferably 3 minutes or more and30 minutes or less, and still more preferably 5 minutes or more and 10minutes or less.

The method of moving the colloidal solution back and forth between theblood inlet port and the blood outlet port is not particularly limitedas long as it is possible to move the colloidal solution back and forth.For example, tubes are connected to the blood inlet port and the bloodoutlet port of the oxygenator, the tube connected to the blood inletport or the blood outlet port is interposed between two pressing plates,and the pressing plates are moved back and forth by a motor, so that itis possible to move the colloidal solution in the blood flow path backand forth. In this case, a flow rate of the colloidal solution movingback and forth can be controlled by adjusting the inner diameter of thetube, the length of the pressing plate, or the frequency at which thepressing plate moves back and forth. An inner diameter of the tube isnot particularly limited, but the inner diameter is preferably 3.0 mm ormore, more preferably 5.0 mm or more, and still more preferably 9.0 mmor more. Further, the inner diameter of the tube is preferably 20.0 mmor less, more preferably 15 mm or less, and still more preferably 11.0mm or less. When the inner diameter is within the above range, a speedof the colloidal solution moving back and forth can be easily adjusted.Further, the shape and material of the pressing plate are notparticularly limited. A plate-like or cylindrical pressing plate may beused. Further, a pressing plate made of metal such as aluminum or ironmay be used. From the viewpoint of ease of controlling the flow rate ofthe colloidal solution, a plate-like pressing plate is preferably used.In addition, the plate made of aluminum is more preferably used from theviewpoint of availability of materials. In a case where the plate-likepressing plate is used, it is possible to control the flow rate of thecolloidal solution moving back and forth by adjusting the length of thepressing plate. At this time, when the length of the pressing plate islong, a larger amount of the colloidal solution can be moved back andforth in the blood flow path by one forward and backward movement of thepressing plate. From this viewpoint, the length of the pressing plate ispreferably 10 mm or more, more preferably 30 mm or more, and still morepreferably 60 mm or more. Further, when the length of the pressing plateis short, the coating step can proceed smoothly. From this viewpoint,the length of the pressing plate is preferably 200 mm or less, morepreferably 160 mm or less, and still more preferably 120 mm or less.Further, a frequency at which the pressing plate moves back and forth ispreferably 0.5 to 5 back-and-forth movements per second, more preferably1 to 4 back-and-forth movements per second, and more preferably 2 to 3back-and-forth movements per second. When the frequency is within theabove range, the efficiency and smoothness of the coating step can bebalanced. The flow rate of the colloidal solution moving back and forthin the blood flow path can be appropriately adjusted, and optimizationconditions for improving the coating amount can be achieved. Further,when the colloidal solution is moved back and forth between the bloodinlet port and the blood outlet port, an amount of the colloidalsolution to be moved is not particularly limited, but is preferably 1L/min·m² or more and 10 L/min·m² or less, preferably 2 L/min·m² or moreand 8 L/min·m² or less, and more preferably 3 L/min·m² or more and 5L/min·m² or less with respect to the membrane area (m²) of the hollowfiber membrane. The colloidal solution is moved at the above rate,whereby the adsorption of the colloid particles to the surface of thehollow fiber membrane proceeds favorably, the coating amount issufficient, and the coating unevenness can be reduced.

In the present specification, “the membrane area” refers to an area ofthe outer surface of the hollow fiber membrane, and is calculated fromthe product of the outer diameter, the circumference ratio, the number,and the effective length of the hollow fiber membrane.

The moving time of the colloidal solution is also not particularlylimited, but is preferably 30 seconds or more and 100 minutes or less,more preferably 1 minute or more and 70 minutes or less, and still morepreferably 1 minute or more and 30 minutes or less in consideration ofthe coating amount, the ease of forming the coated film, and the effectof reducing coating unevenness. In addition, a contact temperature ofthe colloidal solution and the hollow fiber membrane (circulationtemperature of the colloidal solution to the blood flowing side of theoxygenator) is preferably 5° C. to 40° C., and more preferably 15° C. to30° C. in consideration of the coating amount, the ease of forming thecoated film, and the effect of reducing coating unevenness.

In one embodiment of the present invention, in the method formanufacturing an oxygenator, preferably, the lumens of the hollow fibermembranes are used as a gas flow path, and carbon dioxide gas is passedthrough the gas flow path while simultaneously moving the colloidalsolution between the blood inlet port and the blood outlet port. Thus,the aggregation of the colloid particles in the colloidal solution andthe adsorption of the colloid particles to the outer surface of thehollow fiber membrane further progress. A mechanism is presumed asfollows. That is, it is considered that the colloid particles (surfacesof particles) of the antithrombotic polymeric compound contained in thecolloidal solution are negatively charged, and cations exist around thecolloid particles so as to neutralize this charge. In other words, it isassumed that the colloid particles are in a state of forming an electricdouble layer. A theory of electrostatic repulsion based on the electricdouble layer is known as the Derjaguin-Landau-Verwey-Overbeek (DLVO)theory. According to this theory, the total potential energy of theforce acting between the colloid particles is the sum of the potentialenergy of the electric repulsion and the potential energy of the van derWaals attraction. In order to allow the particles to aggregate closetogether, the particles need to cross a peak of total potential energy.If the peak of potential energy is much higher than a thermal kineticenergy of the particles, it is not possible to exceed the peak.Therefore, even if the particles approach, the particles are repulsedand do not aggregate, and the colloid is stable. The electric repulsionis stronger as the thickness of the electric double layer is larger.However, as the electrolyte concentration in the solution is higher, thediffusion layer is compressed and the thickness of the electric doublelayer is reduced. Therefore, when carbon dioxide gas is blown into acolloidal solution containing colloid particles having an electricdouble layer, carbon dioxide is dissolved in water, and hydrogencarbonate ions (HCO₃ ⁻), carbonate ions (CO₃ ²⁻), and hydrogen ions (H⁺)are generated. The thickness of the electric double layer is reduced andthe electric repulsion is reduced, whereby the colloid particles easilyaggregate. At this time, a similar phenomenon occurs not only betweenthe colloid particles but also between the outer surface of the hollowfiber membrane and the colloid particles, and it is considered that thecolloid particles are likely to be adsorbed on the outer surface of thehollow fiber membrane.

The flow rate of carbon dioxide gas is not particularly limited, but ispreferably 0.5 L/min·m² or more and 20 L/min·m² or less, more preferably1 L/min·m² or more and 10 L/min·m² or less, and still more preferably 2L/min·m² or more and 5 L/min·m² or less with respect to the membranearea (m²) of the hollow fiber membrane. The carbon dioxide gas iscirculated at the above rate, whereby the aggregation of the colloidparticles and the adsorption of the colloid particles to the outersurface of the hollow fiber membrane proceed favorably, the coatingamount is sufficient, and the coating unevenness can be reduced. In thepresent specification, a volume (L) of carbon dioxide gas means a volumeat 25° C. and 1 atm.

When circulating the carbon dioxide gas, another gas (for example, aninert gas such as nitrogen gas) may be circulated in addition to thecarbon dioxide gas. However, it is preferable that a ratio of the gas besmaller than a ratio of the carbon dioxide gas from the viewpoint ofobtaining an oxygenator with a sufficient coating amount and lesscoating unevenness. Specifically, a circulation amount (volume) of thegas is preferably 0% by volume or more and 50% by volume or less, morepreferably 0% by volume or more and 20% by volume or less, and mostpreferably 0% by volume with respect to a circulation amount (volume) ofthe carbon dioxide gas.

After coating the hollow fiber membrane with the above colloidalsolution, the coated film is dried to form a coat (coating) of theantithrombotic polymeric compound of the present invention on the outersurfaces of the hollow fiber membranes. Here, a drying condition is notparticularly limited, as long as it is a condition where the coat(coating) of the antithrombotic polymeric compound according to thepresent invention can be formed on the outer surfaces (and optionally,on the outer surface layers) of the hollow fiber membranes.Specifically, a drying temperature is preferably from 5° C. to 50° C.,and more preferably from 15° C. to 40° C. Further, drying time ispreferably 60 to 300 minutes, and more preferably 120 to 240 minutes.Alternatively, the coated film may be dried by continuously or graduallyflowing gas preferably at 5° C. to 40° C., more preferably at 15° C. to30° C., into the hollow fiber membranes. Here, the types of the gas arenot particularly limited as long as a gas has no influence on the coatedfilm and the coated film can be dried thereby. Specific examples thereofinclude air, an inert gas such as nitrogen gas, argon gas, and the like.A circulation amount of the gas is not particularly limited as long asit is an amount at which the coated film can be sufficiently dried, butis preferably 5 to 150 L/min, more preferably 30 to 100 L/min, and stillmore preferably 50 to 90 L/min.

The method for manufacturing an oxygenator according to the presentinvention is used, so that it is possible to manufacture a hollow fibermembrane oxygenator of an outside blood flow type that has a coatingcontaining a sufficient amount of the antithrombotic polymeric compoundon the outer surfaces of the hollow fiber membranes (hereinafter, simplyreferred to as “oxygenator”). According to the method for manufacturinga hollow fiber membrane oxygenator of an outside blood flow type, thereis also provided a hollow fiber membrane oxygenator of an outside bloodflow type that has a coating on outer surfaces of the hollow fibermembranes containing the antithrombotic polymeric compound in an amountof 5 mg/m² surface or more and 100 mg/m² surface or less. An amount ofthe antithrombotic polymeric compound in the coating is more preferably10 mg/m² surface to 60 mg/m² surface, and still more preferably 15 mg/m²surface to 50 mg/m² surface. When the coating amount of theantithrombotic polymeric compound is 5 mg/m² or more, an oxygenatorhaving excellent antithrombotic activity can be obtained. On the otherhand, an upper limit of a coating amount is not particularly limited,but is preferably 100 mg/m² or less. When the coating amount is such avalue, a decrease in the gas exchange capacity due to an excessivelythick coating containing the antithrombotic polymeric compound issuppressed, and an oxygenator having excellent in gas exchange capacitycan be obtained. As the above coating amount, a value measured by amethod described in the following examples is employed.

As described above, the oxygenator according to the present invention iscoated with a sufficient amount of the antithrombotic polymericmaterial, so that the antithrombotic activity on the outer surface sideof the hollow fiber membrane is improved. Therefore, when the oxygenatoris incorporated into the extracorporeal circuit and the blood iscirculated, a platelet count maintenance rate of the circulated blood isimproved. Specifically, the platelet count maintenance rate aftercirculating the blood for 30 minutes is preferably more than 70%, morepreferably 80% or more, and particularly preferably 90% or more (upperlimit: 100%).

EXAMPLES

Effects of the present invention will be explained using the followingexamples and a comparative example. However, the technical scope of thepresent invention is not limited only to the following examples. In thefollowing examples, operation was performed at room temperature (25° C.)unless otherwise specified. In addition, unless otherwise specified, “%”and “parts” mean “% by mass” and “parts by mass”, respectively.

[Synthesis of Antithrombotic Polymeric Compound]

Preparation Example 1: Synthesis of PMEA Having Weight Average MolecularWeight of 350,000

35 g (0.27 mol) of 2-methoxyethyl acrylate (MEA) was dissolved in 160 gof methanol and put in a 4-necked flask, and N₂ bubbling was carried outat 50° C. for 1 hour to prepare a monomer solution. Additionally, 0.035g of 2,2′-azobis(4-methoxy-2,4-dimethylvaleronitrile) (V-70,manufactured by Wako Pure Chemical Industries, Ltd.) was dissolved in 5g of methanol to prepare a polymerization initiator solution. Next, thispolymerization initiator solution was added to the monomer solution, andthe polymerization reaction was carried out at 50° C. for 5 hours. Afterpolymerization for a predetermined time, the polymerization solution wasadded dropwise to ethanol, and the precipitated polymer (PMEA) wasrecovered. When a weight average molecular weight of the recoveredpolymer was measured, the weight was 350,000.

[Preparation of Colloidal Solution]

Example 1-1: Colloidal Solution Having PMEA Concentration of 0.04% byMass

0.48 g of PMEA (weight average molecular weight=350,000) synthesized inPreparation Example 1 was dissolved in 48 g of methanol. To anothercontainer, 1140 g of RO water was added, and the methanol solution ofPMEA as described above was added at an addition rate of 2400 g/min.Thereafter, the mixture was stirred at 25° C. for 3 minutes to obtain awhite turbid colloidal solution. The colloidal solution was a colloidalsolution in which the colloid of PMEA was dispersed.

[Production of Oxygenator]

A hollow fiber membrane oxygenator of an outside blood flow type thathas a membrane area (area of the outer surfaces of the hollow fibermembranes) of 0.5 m² was produced, and the oxygenator is wound around byporous hollow fiber membranes for gas exchange made of porouspolypropylene having an inner diameter of 195 μm, an outer diameter of295 μm, a wall thickness of 50 μm, a porosity of about 35% by volume,and a hole size of the outer surfaces (that is, an average diameter ofthe opening portions) of 80 nm are wound.

Example 1

Tubes (inner diameter 9.5 mm×outer diameter 14.2 mm) were connected tothe blood inlet port and the blood outlet port of the above oxygenator,and the tube connected to the blood inlet port was interposed betweentwo aluminum plates. 96 g of the colloidal solution prepared as abovewas put in the tubes in the oxygenator, and the end of the tubeconnected to the blood inlet port was clamped. While flowing carbondioxide gas from the gas inlet port to the gas outlet port of theoxygenator at a flow rate of 4 L/min·m² from the gas port, one of thealuminum plates (length: 91 mm) was moved back and forth by a motor with2 back-and-forth movements per second. Then, the colloidal solution wasmoved back and forth for 1 minute. The closest distance between the twoaluminum plates was 4.5 mm. At this time, the amount of the movedcolloidal solution was 3 L/min·m² with respect to the membrane area (m²)of the hollow fiber membrane. The tubes were removed from the oxygenatorand the liquid was drained and collected. Then, air was blown at 80L/min to further collect the liquid. The drying was continued while theair was kept flowing.

[Measurement of Concentration of Carbon Dioxide GAS in ColloidalSolution]

Since the colloidal solution and water are considered to dissolve carbondioxide gas to the same extent, instead of measuring a concentration ofcarbon dioxide gas in the colloidal solution, a concentration of carbondioxide gas in water under the same conditions was measured.

First, 500 ml of RO water was put into a beaker, carbon dioxide gas wasbubbled at 2 L/min, and a partial pressure of carbon dioxide gas wasmeasured with a blood gas analyzer and the conductivity was measuredwith a conductivity meter. Then, the conductivity was plotted on thehorizontal axis and the partial pressure of carbon dioxide gas wasplotted on the vertical axis, and then the approximate Expression (2)was obtained:partial pressure of carbon dioxide gas (mmHg)=18.587×conductivity(μs/cm)−237.63

200 ml of RO water was put into a closed circuit including a hollowfiber membrane oxygenator of an outside blood flow type, a bag made ofvinyl chloride, and a tube, and carbon dioxide gas was circulated fromthe gas inlet port to the gas outlet port of the hollow fiber membraneoxygenator of an outside blood flow type at 2 L/min (4 L/min·m²). ROwater before circulation and RO water 5 minutes after the start ofcirculation were sampled and measured with the blood gas analyzer andthe conductivity meter.

The RO water before circulation could not be measured because theconcentration of carbon dioxide gas was below the measurement lowerlimit (5 mmHg) of the blood gas analyzer. In addition, RO water 5minutes after the start of circulation could not be measured because theconcentration of carbon dioxide gas exceeded the measurement upper limit(250 mmHg), but the conductivity was 42.1 μS/cm, so the partial pressureof carbon dioxide gas was calculated as 544 (mmHg) from Expression 1.

From the above results, it is considered that the concentration ofcarbon dioxide gas in the coating liquid is 5 mmHg or less in a casewhere no carbon dioxide gas flows, and about 544 (mmHg) in a case wherethe carbon dioxide gas flows, similarly to the concentration of carbondioxide gas in water.

[Measurement of Coating Amount]

The housing of the oxygenator was cut and disassembled with anultrasonic disc cutter, and the hollow fiber membrane was cut with acutter. A total amount of the hollow fiber membranes was put into aglass bottle with a cap, acetone was added, and the mixture wasextracted with an ultrasonic cleaner for 1 hour. 46 g of the acetoneextract was collected in another glass bottle with a cap, and acetonewas evaporated by heat block. Then, the evaporated and dried product wasdissolved in 10 mL of tetrahydrofuran. The dissolved colloidal solutionwas shaken for 1 hour with a shaker, and dissolved for 1 hour with anultrasonic cleaner. The resultant colloidal solution was filtratedthrough a 0.45 μm filter, and the filtrate was quantified by gelpermeation chromatography (GPC). Specifically, a THF solution (standardsolution) containing 1 mg/mL of PMEA was analyzed using GPC, and an areaof a peak corresponding to PMEA was calculated. Subsequently, a THFsolution (test solution) of the evaporated and dried product wasanalyzed using GPC, and an area of a peak corresponding to PMEA wascalculated in the same manner as described above. Thereafter, the amountof PMEA in the test solution was calculated using the followingExpression (3), and the coating amount of PMEA per 1 m² of the membraneof the oxygenator (an area of the outer surface of the hollow fibermembrane: 1 m²) was calculated using Expression (5).amount of PMEA in test solution (mg)=(area of peak of test solution/areaof peak of standard solution)×10  Expression (3):total amount of PMEA (mg)=amount of PMEA in test solution (mg)×(totalamount of acetone/amount of recovered acetone)  Expression (4):coating amount of PMEA on oxygenator (mg/m²)=total amount ofPMEA/(weight of oxygenator subjected to extraction×area of membrane per1 g of oxygenator)  Expression (5):

[Colloid Use Efficiency]

After the coating, part (32 mL) of the colloidal solution wasdischarged, and the discharged colloidal solution was dried by heatblock and vacuum drying, and then dissolved in 1.5 mL oftetrahydrofuran. The dissolved colloidal solution was shaken for 1 hourwith a shaker, and dissolved for 1 hour with an ultrasonic cleaner. Theresultant colloidal solution was filtrated through a 0.45 μm filter, andthe filtrate was quantified by gel permeation chromatography (GPC).Specifically, the amount of PMEA in the discharged colloidal solutionwas calculated by the same method as in Expression (3) as describedabove. Thereafter, the amount of PMEA in the whole colloidal solutionafter coating was calculated using the following Expression (6), and thecolloid use efficiency was calculated using the following Expression(7).amount of PMEA in whole colloidal solution after coating (mg)=amount ofPMEA in discharged colloidal solution×(amount of whole colloidalsolution/amount of discharged colloidal solution)  Expression (6):colloid use efficiency=(1−(amount of PMEA in whole colloidal solutionafter coating/amount of PMEA in whole colloidal solution beforecoating))×100(%)  Expression (7):

Example 2

Tubes (inner diameter 9.5 mm×outer diameter 14.2 mm) were connected tothe blood inlet port and the blood outlet port of the above oxygenator,and the tube connected to the blood inlet port was interposed betweentwo aluminum plates. The above colloidal solution was put in the tubesin the oxygenator, and the end of the tube connected to the blood inletportion was clamped. Without using carbon dioxide, one of the aluminumplates (length: 91 mm) was moved back and forth by the motor with 2back-and-forth movements per second, whereby the coating liquid wasmoved back and forth for 1 minute. The closest distance between the twoaluminum plates was 4.5 mm. The tubes were removed from the oxygenatorand the liquid was drained and collected. Then, air was blown at 80L/min to further collect the liquid. The drying was continued while theair was kept flowing.

The measurement of the coating amount and the measurement of the colloiduse efficiency were performed in the same manner as in Example 1.

Comparative Example

Tubes (inner diameter 9.5 mm×outer diameter 14.2 mm) were connected tothe blood inlet port and the blood outlet port of the above oxygenator.The colloidal solution was put in the tubes in the oxygenator, and thecoating liquid was held (without movement) for 1 minute. The tubes wereremoved from the oxygenator and the liquid was drained and collected.Then, air was blown at 80 L/min to further collect the liquid. Thedrying was continued while the air was kept flowing.

The measurement of the coating amount and the measurement of the colloiduse efficiency were performed in the same manner as in Example 1.

The measurement results of the coating amount are shown in FIG. 8, andthe measurement results of the colloid use efficiency are shown in FIG.9. In Examples 1 and 2, it was found that the colloid use efficiency wasimproved and the coating amount of the colloidal solution on the hollowfiber was increased as compared with the comparative example. Further,among the examples, the colloid use efficiency of Example 1 is furtherincreased. This can be presumed to be due to the fact that the movementof the coating liquid increased the colloid use efficiency, and theaddition of carbon dioxide further increased the colloid use efficiency.

What is claimed is:
 1. A method for manufacturing an oxygenator having ahousing retaining a hollow fiber membrane bundle, wherein the hollowfiber membrane bundle comprises a plurality of porous hollow fibermembranes for gas exchange which have outer surfaces, inner surfacesforming lumens, and opening portions through which the outer surfacescommunicate with the inner surfaces, wherein the oxygenator defines ablood flow path which is outside of the hollow fiber membranes in thehousing between a blood inlet port and a blood outlet port, the methodcomprising: filling the blood flow path with a colloidal solutioncontaining an antithrombotic polymeric compound; and moving thecolloidal solution along the blood flow path between the blood inletport and the blood outlet port for a time that coats a predeterminedamount of antithrombotic polymeric compound on the outer surfaces of thehollow fiber membranes; wherein the lumens of the hollow fiber membranesare used as a gas flow path, and carbon dioxide gas is passed throughthe gas flow path while moving the colloidal solution between the bloodinlet port and the blood outlet port.
 2. The method for manufacturing anoxygenator according to claim 1, wherein the colloidal solution is movedalternately back and forth between the blood inlet port and the bloodoutlet port.
 3. The method for manufacturing an oxygenator according toclaim 1, wherein the colloidal solution is circulated by a pump coupledto the blood inlet port and the blood outlet port.
 4. The method formanufacturing an oxygenator according to claim 1, wherein a flow rate ofthe carbon dioxide gas is 0.5 L/min·m² or more and 20 L/min·m² or lesswith respect to a membrane area (m²) of a hollow fiber membrane.
 5. Themethod for manufacturing an oxygenator according to claim 1, wherein thecolloidal solution contains 0.01% by mass or more of an antithromboticpolymeric compound.
 6. The method for manufacturing an oxygenatoraccording to claim 1, wherein the antithrombotic polymeric compound hasa structural unit derived from alkoxyalkyl(meth)acrylate represented bythe following Formula (I):

wherein R³ represents a hydrogen atom or a methyl group, R¹ representsan alkylene group having 1 to 4 carbon atoms, and R² represents an alkylgroup having 1 to 4 carbon atoms.
 7. The method for manufacturing anoxygenator according to claim 1, wherein a weight average molecularweight of the antithrombotic polymeric compound is more than 200,000 andless than 800,000.